Method of making a friction disc

ABSTRACT

The invention relates to friction discs of the progressive engagement type, especially for clutches of heavy automobile vehicles, the disc comprising two annular friction linings extending respectively on both sides of and in contact with a cut-out corrugated support, each lining being fixed individually by continuous glueing zones on this support, along parts of the corrugations of the support which are in contact with the lining. The surface area of the glueing zones should be between 5 and 35%, and preferably about 10% of the surface area of the lining. In a modification, each lining is fixed on the support, not only by the glueing zones but also by at least one rivet per zone arranged at right angles to each glueing zone. The riveting operation is preferably carried out after glueing and before the adhesive is polymerized or set.

This is a division of application Ser. No. 639,123, filed Dec. 9, 1975,and now U.S. Pat. No. 4,022,310.

The present invention relates to a friction disc, especially forclutches, this disc being of the gradual or progessive engagement typecomprising two annular friction linings extending respectively on bothsides and in contact with a cut-out corrugated support, each liningbeing individually fixed on this support along parts of the corrugationsof this support which are in contact with the said lining.

The linings are generally fixed to the cut-out and shaped support bymeans of rivets. The applicants have found that no matter how strongthese rivets may be, they do not stand-up satisfactorily to high speedsof rotation, especially above 6,000 r.p.m. for friction linings of heavylorry vehicles, and this may result in the bursting of the linings.

The present invention has for its object a friction disc of theprogressive engagement type, characterized in that each lining is fixedto the cut-out and corrugated support by continuous areas of glueing.The surface of the glueing areas is preferably comprised between 5 and35% of the surface area of the lining.

By virtue of this arrangement, the disc is able to withstand high speedsof rotation.

The cut-out and corrugated support preferably comprises a circularseries of shaped fins, each having at least one portion in contact withone of the linings and at least one portion in contact with the otherlining, and the glueing areas are provided along at least some of thesaid contact portions.

According to another characteristic feature, each lining is fixed to thesupport, not only by the said glueing areas but also by at least onerivet arranged at right angles. to each glueing area.

With such an arrangement, there has been observed a remarkable behaviourof the disc at very high speeds of rotation of the order of 8,000 r.p.m.and even higher, especially with friction linings of heavy vehicles.

The present invention has also for its object a method of manufacture ofa friction disc of this kind.

This method is characterized in that the three elements constituted bythe two linings and the support are manufactured, at least a part ofthese elements is coated with glue, along the regions corresponding tothe glueing areas and, before the glue sets, the riveting operation iscarried out with rivets in order that these latter may play the part ofa joint-clamping means.

This arrangement makes it possible to dispense with putting the discassembly in a press during the setting of the glue and subjecting thesupport to deformation during setting which involves a liability ofdisturbing the conditions of setting.

In addition, this arrangement has the advantage of permitting surfacecoating beyond the actual glueing areas, since the action of the rivetsat the level of these areas alone limits the glueing to these areas.This makes it possible to restrict the precautions to be taken inglueing.

Forms of embodiment of the invention are described below by way ofexample, reference being made to the accompanying drawings in which:

FIG. 1 is a partial view in elevation of a friction disc according tothe invention;

FIG. 2 is a corresponding view of this disc in cross-section, takenalong the broken line II--II of FIG. 1;

FIG. 3 is a partial developed view to a larger scale, in cross sectiontaken along the circumferential line III--III of FIG. 1;

FIG. 4 is a view in elevation of an alternative form of friction discfin;

FIG. 5 is a view in cross-section taken along the line V--V of FIG. 4.

The form of construction shown in FIGS. 1 to 3 relates by way ofnon-restrictive example to a clutch friction disc, especailly for aheavy automobile vehicle. This disc comprises two substantially flatfriction linings 10 and 11 of generally annular shape, extendingrespectively on both sides of a cut-out and corrugated support 12permitting progressive engagement of the disc. The support 12 comprisesa circular series of shaped fins 13 fixed to a disc-plate 14 mounted inturn on a hub 15.

Each shaped fin 13 is adjacent to the lining 10 by a contact portion 16and is adjacent to the lining 11 by a contact portion 17.

Between the portions 16 and 17, the fin 13 extends freely in thenon-clamped condition of the disc, between the linings 10 and 11, exceptat its extremities at 18 when they touch the linin 10, and at 19 whenthey touch the lining 11.

Each fin 13 is fixed to the lining 10 by a glueing zone 20 along theportion 16, and to the lining 11 by a glueing zone 21 along the portion17.

As can be seen from FIG. 1, the glueing zones 20 and 21 are oblong andextend radially along substantially the whole of the radial length ofthe common contact portion between the fins 13 and the linings 10 and11.

The surface area of the glueing zones 20 of the fins 13 on the lining 10or of the glueing zones 21 of the said fins 13 on the lining 11 iscomprised between 5 and 35% and is advantageously in the vicinity of 10%of the surface area of the lining 10 or 11.

In the example shown in FIGS. 1 to 3, the width L of each glueing zone20, 21 is equal to about half the distance D separating the zones 20 and21, this distance being calculated along the circumferential lineIII--III corresponding to the mean radius of the annular linings 10 and11.

In addition, the linings 10 and 11 are fixed to the support 12 by rivets22 and rivets 23 respectively. At least one rivet 22, and preferably tworivets 22 spaced apart radially, are provied at right angles to eachglueing zone 20, whereas, in the same way, two rivets 23 are provided atright angles to each glueing zone 21.

In order to manufacture a disc such as that which has just beendescribed with reference to FIGS. 1 to 3, the elements constituted bythe lining 10, the lining 11 and the support 12 comprising the fins 13are first manufactured. At least part of these elements is coated withglue over at least the regions corresponding to the glueing zones 20 and21. Before the setting or polymerization of the adhesive, the rivetingoperation is carried out with the rivets 22 and 23 in order that, duringthe setting of the adhesive, these latter play the part of ajoint-clamping means. In this way, it becomes unnecessary to put thewhole of the disc assembly in a press during the setting of the glue andavoids subjecting the support to deformation during setting, which isliable to disturb the conditions of setting.

More particularly, the internal faces of the linings 10 and 11 arecoated with cold adhesive applied from a gun, a mask being previouslyarranged on the said faces so as to leave uncovered only the regionscorresponding to the glueing zones 20 and 21.

The three elements 10, 11 and 12 are joined together. The rivetingoperation is carried out before the adhesive is set by means of therivets 22, 23. From that time, these rivets hold together the assembleddisc which can immediately be handled without special precaution and itis only necessary to wait until the polymerization is complete for thedisc to be put into service.

With a disc such as that which has just been described with reference toFIGS. 1 to 3, and having an external diameter of 430 mm. and nine fins13, 10 tests have shown that this disc has an excellent performance at aspeed of rotation of 8,000 r.p.m., whereas tests carried out under thesame conditions with similar discs not provided with glueing zones 20and 21 have shown that the linings burst at a speed of rotation of 6,000r.p.m.

It should be noted that the linings 10 and 11 are directly glued alongthe zones 20 and 21 to the fins 13 themselves.

Reference will now be made to FIGS. 4 and 5, in which the arrangement issimilar to that which has been described with reference to FIGS. 1 to 3,and in which the same elements have been given the same referencenumbers, followed however by a dash index.

In FIGS. 4 and 5 there can be seen at 20' the glueing zone of the fin13' on the lining 10', and at 21' the glueing position of the fin 13' onthe lining 11'. There can be seen at 22' a rivet for fixing the fin 13'on the lining 10'. The rivet 22' is arranged at right angles to theglueing zone 20', while the rivet 23' is disposed at right angles to theglueing zone 21'.

The surface area of the glueing zones 20' for the fins 13' on the lining10', or of the glueing zones 21' of the said fins 13' on the lining 11',is between 5 and 35% and advantageously in the vincinty of 20% of thesurface area of the lining 10' or 11'.

There can be seen at 24 a part of the fin 13' which is close to thelining 10', and at 25 a part of the fin 13' which is close to the lining11'. The parts 24 and 25 are intended to come into contact with thelinings 10' and 11' in order to modulate the conditions of progessivitywhen the thickness of the disc level with the linings is allowed todiminish at the moment of engagement.

The method of manufacture of the disc of FIGS. 4 and 5 is similar tothat which has been described for the disc of FIGS. 1 to 3, but thewhole of the inner faces of the linings 10', 11' are coated withadhesive, without a mask, by a spraying gun. The action of the rivets atthe level of only the zones 20', 21', limits the adhesive to theselatter.

The method applied to the disc of FIGS. 1 to 3 could also be applied tothe disc of FIGS. 4 and 5 or vice-versa. It will be noted that thepolymerization may be carried out equally well in the hot or cold state.

What I claim is:
 1. A method of manufacture of a friction disc of theprogressive engagement type, said method comprising the steps of: firstmanufacturing three elements constituted by two flat annular frictionlinings and a cut-out and corrugated support; coating with adhesive atleast a part of these elements at least over the regions correspondingto glueing zones which zones include the parts of the corrugations ofthe support which are in contact with said linings; and carrying out ariveting operaton with rivets in said glueing zones before setting ofthe adhesive, whereby said rivets play the part of a joint-clampingmeans during the setting of said adhesive.
 2. A method as claimed inclaim 1, in which the inner faces of said friction linings are coatedwith adhesive before riveting.
 3. A method as claimed in claim 1, inwhich regions of at least a part of the inner faces of said frictionlinings which correspond exactly to said glueing zones are coated withadhesive before riveting.
 4. A method as claimed in claim 1, in whichregions of at least a part of the inner faces of said friction liningswhich extend beyond said glueing zones are coated with adhesive beforeriveting.
 5. A method as claimed in claim 4, in which the whole of theinternal faces of said friction linings is coated with adhesive beforeriveting.